ABCD PUMPS - Model 2020: User and Maintenance Manual
ABCD PUMPS - Model 2020: User and Maintenance Manual
ABCD PUMPS - Model 2020: User and Maintenance Manual
• Technical Description
• Usage and Maintenance Instructions
• Parts Catalogue
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User and Maintenance Manual
Table of contents
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User and Maintenance Manual
Glossary
B
Bearing lantern
Assembly that keeps contaminants and liquids out of the stuffing box to protect the bearings. - 3
C
Cable glands
Detachable devices that clamps over cable exteriors as it enters enclosure for sealing against
ingress of dirt/moisture and avoid mechanical damage to the cable. - - - - - - - - - - - - - 6
Cavitation
Bubbles formed due to low pressure around the pump impeller. These bubbles can cause damage
to the impeller and/or the pump housing. - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Circuit breaker
Electrical switch that automatically disconnects supply due to an electrical overload. - - - - - 15
D
Dynamic balancing
Balancing of a rotating object to mitigate forces in direction other than the axis of rotation to avoid
the vibrations and uneven running. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
E
End suction
Centrifugal pump with casing having suction at one end and discharge at the top. - - - - - - - 1
F
Fastener
Hardware device for mechanically joining or affixing two or more assemblies, like bolts, nuts,
washers, etc. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Flange
An external or internal ridge to help connect sections of pipes. - - - - - - - - - - - - - - - - 6
Foundation bolt
High tensile bolts used to connect equipment to the concrete foundations. - - - - - - - - - - 6
G
Gasket
Seal made from softer material to fill the space between two or more mating surfaces to prevent
leakages. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
Grouting
Filling space in a hole with bolt with cement to seal the gap and strengthen the joint. - - - - - 6
H
Head
Height to which a pump can raise water. - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
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High-tensile fastener
These fasteners are made from carbon steel or tempered alloy steel to provide an increased tensile
strength that allows stronger joints. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
I
Impeller
Rotating part of a centrifugal pump, that moves a fluid by rotation. - - - - - - - - - - - - - - 1
L
Lovejoy
Three-piece couplings with spider-shaped cushion between two hubs that reduces shock and
allows minor shaft misalignment. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6
N
Non-return check valve
A valve that allows only one-way movement of liquid and blocks the return flow. - - - - - - - 12
Nylock
A nut with a nylon-insert to increase friction on the screw thread and prevent becoming loose due
to vibration. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
P
Packing
Flexible or rope-like material inside the stuffing box to improve sealing of the shaft. - - - - - - 21
Prime
Filling the pump body with liquid prior to starting. Priming the pump allows best liquid transfer
efficiency and avoids dry running that damages the pump seals. - - - - - - - - - - - - - - - 14
R
RPM
Revolutions per minute, unit of a shaft’s rotation speed. - - - - - - - - - - - - - - - - - - - 2
S
Seal
Annular element around a rotating shaft to prevent loss of pressure on one side of the seal. - - 1
Spring-washer
A washed with spring-like deformation to prevent loosening of fasteners due to vibrations. - - 11
Stencil
Sheet with holes for transferring marking to the underlying surface. - - - - - - - - - - - - - - 6
Stuffing box
Assembly housing a seal that prevents leakage of liquid on a rotating shaft. - - - - - - - - - - 3
T
TEFC
Totally enclosed fan cooled, a type of electric motor. - - - - - - - - - - - - - - - - - - - - - 5
V
Volute
Casing of a centrifugal pump receiving liquid from the impeller. - - - - - - - - - - - - - - - - 1
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Introduction to Model 2020 pump
Highlights
ABCD Pumps’ Model 2020 lifts clear and mildly turbid water over a
maximum head of 30 meters.
• The pump seals are made from a specially formulated alloy for a
long service life and ability to withstand high volute pressures.
• The pump can handle water over a wide temperature range to suit
varied applications.
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Features
Parameter Value
Head 30 meters
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User and Maintenance Manual
Details of pump
Pump casing
• High efficiency volute type pump with top, side, and 45 degrees
orientations.
Impeller
Shaft
Stuffing box
Bearing
Lubrication
Drive
Application
• Irrigation systems
• Air-conditioning systems
• Industrial processes
Animation
Note
Animation will play only in the online version of this manual.
Delivery options
Basic pump
In this option, we offer only the basic model 2020 pump. You have to
do the following tasks to make a functional pump-set. You may use the
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User and Maintenance Manual
following drawing for manufacturing the base frame that mounts the
pump and motor: “Foundation plate” on page 10
Basic pump
To commission a basic pump, you have to select and install the
following sub-assemblies on the foundation plate:
• Motor
• Coupling
Integrated pump-set
To save time and efforts for end user, model 2020 pump is available as
a complete ready-to-use module with factory integrated and aligned
sub-assemblies. The combination is supplied with comprehensive
performance test certificate and integrated warranty.
This combination consists of:
• Siemens or Crompton make 3.7 kW, 415 VAC, 3 phase TEFC motor
◊ Priming arrangement
◊ Electrical panel
◊ Electrical wiring
Dimensions
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[+ROHV
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Installation
Note
Only trained and qualified technicians should install the pump.
Order options
• Order only the basic model 2020 pump. See “Basic pump” on
page 5.
[+ROHV
Concrete platform
[+ROHV
[+ROHV
[+ROHV
[+ROHV
Foundation plate
2. Drill and insert M20 anchor bolts to the concrete for mounting the
foundation plate. Use grouting compound for securing anchor bolts
to the concrete.
3. Fabricate the foundation plate for mounting pump and motor. Use
the drawing of “Foundation plate” on page 10 as a reference.
5. Align the motor shaft with the pump shaft using shims within ± 0.5
mm.
6. Add and tighten a ‘Lovejoy’ coupling between the motor and pump
shaft.
Note
Use high-tensile fasteners. Use plain washers to spread the force. Use
spring-washers to ensure fastener tightness under service conditions.
As an alternate to spring-washers, use Nylock® nuts with plain
washers.
Note
Use high-tensile fasteners with Nylock® nuts.
9. Couple the inlet and outlet pipes to the flanges. Use gaskets
between the pump and pipe flanges. Tighten the fasteners to 125
Nm torque.
Note
If the water level is below the inlet flange, fit a non-return check valve
at the bottom of inlet pipe.
Note
Ensure that the inlet pipe has provisions to connect external water
supply to prime the pump, prior to starting.
Note
Power the pump only for a second to check the direction of rotation.
13. Prime the pump and check for leakages before powering the
motor. See “Priming the pump” on page 16.
Note
Only authorized and trained personnel should operate and maintain
the pump.
1. Press the Stop switch on the control panel to stop the pump.
2. Disconnect the incoming supply to the control panel by opening the
circuit breaker.
Pre-starting checklist
Note
The control panel should have protection for loss of phase, reversal of
phase, under-voltage, over-voltage, overloads, and dry-running.
4. All guards are installed, control panel doors are closed, all inlet and
outlet valves are in the open position.
Note
Pump seals and casing will get damaged if it runs with closed inlet and
outlet valves.
2. Check water pressure on the delivery side. Ensure that the water
pressure does not fluctuate excessively.
3. Check for current consumption in each phase and confirm that the
three phase current readings are nearly the same.
4. Check that motor has a flow of cooling air over its frame and that it
is not heating excessively.
Post-starting checklist
Perform the first procedure if the pump does not run regularly, or is
started after a long time, or if you suspect that the non-return check
valve at the bottom of the inlet pipe is defective.
1. After starting the pump, open the priming water inlet valve on the
incoming flange.
4. Check the motor current in all three phases and ensure that the
load is balanced.
Note
The rotor seals will get permanently damaged if the pump runs
without water. Prime the pump only when it is not running.
4. Close and secure the priming bleed bolt trapping the water in the
pump casing. [6]
5. Close the priming inlet valve [7].
6. Stop and disconnect the external source of water from the priming
inlet [8].
7. Your pump is now primed and ready to move water from lower
levels to full-head heights.
You may need to drain the pump casing before doing maintenance on
bearings or the seals.
Note
Drain the pump only when it is not running.
Note
Be prepared to collect the water that may flow from pump casing after
you open the drain hole.
Daily maintenance
• Inspect the seal, paying attention to the lip for cuts or irregularities.
Note
Check coupling and bolts only if the pump is not running.
• Ensure that the coupling guard is present and secure to base plate.
• Check the mechanical seal if the pump has sitting idle for some
time. Replace if required.
• Top-up grease or oil for the bearings via external lubrication cup or
grease nipple. Fill oil in cup to the maximum marking. Push grease
into the nipple via a grease gun until the operating handle becomes
tough to move.
• Check the shaft alignment and call ABCD service if movement is >
100 uM.
Annual maintenance
Note
If in doubt, always consult the ABCD Pumps’ service department.
For spares and service of the motor or coupling, inform their nearest
authorized technical partners, whose details are available your local
ABCD Pumps representatives.
Views
The following pages contain illustrated spare list of the basic pump and
the integrated pump-set.
Note
The active links between parts in the images and tabulated list will
display only in the online manual.
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User and Maintenance Manual
Integrated pump-set
4 2
12 3
1
13
15
7
11
16 5
10
14
9
14
12 8
13
16 14 19 20 12 14 13
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Index
A
Animation .............................................................................................................................4
Application ............................................................................................................................4
D
Delivery options
Basic pump ....................................................................................................................4
Integrated pump-set .......................................................................................................5
Details of pump
Bearing ...........................................................................................................................3
Drive ...............................................................................................................................4
Impeller ..........................................................................................................................3
Lubrication .....................................................................................................................3
Pump casing ..................................................................................................................3
Shaft ...............................................................................................................................3
Stuffing box ....................................................................................................................3
Dimensions ...........................................................................................................................7
Draining the pump ..............................................................................................................19
H
Highlights
Features .........................................................................................................................2
I
Installation
Installation of basic pump ..............................................................................................9
Installation of integrated pump-set ...............................................................................14
Order options .................................................................................................................9
M
Maintenance
Annual maintenance ....................................................................................................22
Daily maintenance .......................................................................................................21
Maintenance, every three months ................................................................................22
P
Priming the pump ...............................................................................................................16
S
Spare parts .........................................................................................................................23
Views ...........................................................................................................................23
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User and Maintenance Manual
U
Using the pump-set
During running checklist ...............................................................................................16
Post-starting checklist ..................................................................................................16
Pre-starting checklist ....................................................................................................15
Starting the pump .........................................................................................................15
Stopping the pump .......................................................................................................15
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